Procedure
‘
Procedure Title: Field Period Assembly Station One
Number:
D-NCSX-FPA-001 / Revision:
0 / Effective Date:
Expiration Date:
(2 yrs. unless otherwise stipulated)
Procedure Approvals
Author: John W. Edwards / Date:
ATI: / Date:
RLM: Larry Dudek / Date:
Responsible Division: NCSX Project
Procedure Requirements
Designated by RLM
LABWIDE:
X / Work Planning Form (ENG-032) / Lockout/Tagout (ESH-016)
Confined Space Permit (5008,SEC.8 Chap 5) / Lift Procedure (ENG-021)
Master Equip. List Mod (GEN-005) / X / ES&H Review (NEPA, IH, etc.) NEPA 1283
RWP (HP-OP-20) / Independent Review
ATI Walkdown / X / Pre-Job Brief
X / Post-job Brief *
D-SITE SPECIFIC:
X / D-Site Work Permit (OP-AD-09) / Door Permit (OP-G-93)
Tritium Work Permit (OP-AD-49) / USQD (OP-AD-63)
X / Pre-Job Brief (OP-AD-79) / T-Mod (OP-AD-03)
/ ** DCA/DCN (OP-AD-104) #
* Required for installations involving internal vacuum installations, critical lifts, and for the initial installation of repetitive work.
** OP-AD-104 was voided by procedure ENG-032. However, DCA’s that were open at the time of adoption of ENG-032 are still considered valid for work approval purposes.
REVIEWERS (designated by RLM) Rec’d/Incorp.
Comments
Accountable Technical Individual. …………John W Edwards
Test Director
Independent Reviewer Hutch Neilson
D-Site Shift Supervisor
Independent
NCSX Dimensional Control Coordinator ……………………….Brent Stratton
Vacuum
NCSX Field Supervisors… Steve Raftopoulos, Mike Viola
Project Engineer for Stellerator Systems (WBS 1) Manager……Brad Nelson (ORNL)
WBS Manager for Modular Coils (WBS14).. …………………Dave Williamson (ORNL)
Quality Assurance/Quality Control. ……Judy Malsbury, J. Boscoe, Colin Phelps
Maintenance and Operations Division
Energy Conversion System/Motor Control Division
Engineering ……………………………………..
Environmental Restoration & Waste Management Division
Environmental, Safety & Health……………………………………Jerry Levine
Industrial Hygiene………………………………………………... Bill Slavin
Health Physics…………………
RLM ………………………………………………………………..Larry Dudek
TRAINING (designated by RLM)
No training required ______/ Instructor John Edwards
Personnel (group, job title or individual name) / Read Only / Instruction
Pre-job
Briefing / Hands OnLead Tech. / X
Technicians performing task / X
Field Supervisors / X
Quality Control Representative / X
Training Rep.
RLM Larry Dudek
Field Period Assembly Station One
D-NCSX-FPA-001
RECORD OF CHANGE
Revision / Date / Description of Change00 / XXXX / Initial release
TABLE OF CONTENTS
1 Scope 1
1.1 Introduction 1
1.2 Scope 1
1.3 Identification of Vacuum Vessel Segment: 1
2 Applicable Documents 1
2.1 NCSX-MIT/QA-XXXXX: 1
2.2 NCSX-PLAN-CMFOP-00: 1
2.3 D-L-NCSX-XXX Lifting Vacuum Vessel Segment 1
2.4 D-NCSX-XXXX Dimensional Control & Metrology for the NCSX VV 1
2.5 D-NCSX-PLAN-FPA1DC-XX VV Dimensional Control Plan 2
3 Safety Requirements: 2
3.1 Job Hazard Analysis: 2
4 Prerequisites & Conditions: 2
4.1 Pre-Job Briefing: 2
4.2 Daily Operations Startup and Shutdown: 2
5 Materials and Parts for this station 2
6 Fabrication Process 3
6.1 Daily Startup Activities: 3
6.2 Daily Shutdown Activities: 3
6.3 Moving VVSA from Shipping Pallet: 4
6.4 Installation of VVSA on Turning Fixture: 4
6.5 Inspect VVSA: 6
6.6 Metrology Set-Up and Dimensional Inspection: 6
6.7 Marking Flux Loop Template and Heating Coolant Stud Locations: 7
6.8 Installation of Flux Loop Templates: 9
6.9 Installation of Heating Collant Studs: 9
6.10 Installation of Flux-Loops and Routing Leads: 10
6.11 As Built Dimensional Inspection of Flux Loops: 10
6.12 Flux Loop Termination and Template Removal: 11
6.13 Installation of Heating Coolant Tubes: 11
6.14 Dimensional Inspection: 15
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
6.25
7 Completion of Activities at Station One: 58
7.1 Document Verification: 58
7.2 Field Package: 58
7.3 Approval: 59
Index of Figures
Figure 1- Turning Fixture
Figure 2-
Figure 3-
Figure 4-
Figure 5-
Figure 6-
Figure 7-
Figure 8-
Figure 9-
Figure 10-
Figure 11-
Figure 12-
Figure 13-
Figure 14-
Figure 15-
Figure 16-
Figure 17-
Figure 18-
Figure 19-
Figure 20-
Index of Tables
Table 1-
Table 2-
Table 3-
Table 4-
i
Field Period Assembly Station One
D-NCSX-FPA-001
1 Scope
1.1 Introduction
The Field Period Assembly is divided into 5 workstations. Each workstation has a specific set of tasks that will be performed as part of the overall assembly process. This procedure addresses the manufacturing, inspection, test and QC inspection points for a specific workstation.
- Station No. 1… Vacuum Vessel Subassembly (VVSA) Activities
1.2 Scope
This procedure is used to describe the assembly sequence required for Station 1 Field Period Assembly.
- Installing the Vacuum Vessel in the turning fixture
- Metrology measurements
- Flux Loop Locations
- Heating Cooling Tube Stud Locations
- Installation of Flux Loops
- Installation of Heating –Cooling Tubes
-
1.3 Identification of Vacuum Vessel Segment being Assembled:
Segment Number: ______
2 Applicable Documents
2.1 NCSX-MIT/QA-XXXXX:
All applicable documents associated with this procedure, are identified in the MIT/QA Plan, document number NCSX-MIT/QA-XXXXX.
2.2 NCSX-PLAN-CMFOP-00:
All work processes are governed by the “NCSX Coil Manufacturing Facility Operations Plan”, document number NCSX-PLAN-CMFOP-00.
2.3 D-L-NCSX-XXX Lifting Vacuum Vessel Segment
2.4 D-NCSX-XXXX Dimensional Control & Metrology for the NCSX VV
2.5 D-NCSX-PLAN-FPA1DC-XX VV Dimensional Control Plan
3 Safety Requirements:
All work will be performed in a safe manner in accordance with PPPL Environmental Safety & Health Directives ES&H 5008 and the “Integrated Safety Management” (ISM) policy.
3.1 Job Hazard Analysis:
A JHA will be generated for each Vacuum Vessel Sub Assembly station, identifying existing or potential workplace hazards and to evaluate the risk of worker injury or illness associated with job tasks. (Reference document ESH-004 “Job Hazard Analysis”) The IH representative will review the JHAs for accuracy as well as completeness. It will be reviewed with all activity participants at the Pre-Job briefings.
4 Prerequisites & Conditions:
4.1 Pre-Job Briefing:
A pre-job briefing will be held, describing the processes and safety issues prior to starting any part of this procedure. Attendance shall be documented via training sign-in sheet.
Pre job Briefing complete: ______
VVSA Field Supervisor Date
4.2 Daily Operations Startup and Shutdown:
Each working day, it is required to complete and initial the daily operations startup log to ensure that the station is ready to commence work activities for the day. The signoff log is located in the Daily Station Log. See section 6.1 and 6.2 for details.
5 Materials and Parts for this station
The following materials and/or equipment will be used with this procedure.
General Description / Material / Reference Document/Product No.6 Assembly Process
This assembly procedure is to be used as guide to complete the station no. 1 activities. Deviation from this procedure for processes that DO NOT affect the design of the assembly can be made during the assembly process with the concurrence of the VVSA Field Supervisor. All deviations shall be documented in the procedure and initialed by the VVSA Field Supervisor prior to implementing the deviations. Deviations that may effect the design of the coil requires a Request for Deviation “RFD” approval. The RFD must be approved prior to proceeding. Procedure changes need to be incorporated into the document via “Minor Procedure Changes” or “Revisions”.
6.1 Daily Startup Activities:
6.1.1 Check all daily supplies needed:
6.1.2 Verify operation of all equipment needed that day.
6.1.3 Check station for cleanliness
6.1.4 Check that safety equipment needed for day’s activities are available
6.1.5 Check that the day’s travelers and procedures are in their document holder.
6.1.6 Once completed, date and initial daily log at the back of the Station Log Book.
6.2 Daily Shutdown Activities:
6.2.1 Turn off power to equipment not in use.
6.2.2 Clean entire workstation area.
6.2.3 Verify that all Traveler and data sheet information is complete.
6.2.4 The Lead Technician shall verify that the Station’s Log Book has been completed and signed for the day.
6.2.5 Once completed, date and initial daily log at the back of the Station Log Book.
6.3 Vacuum vessel Receipt and Inspection:
6.3.1 Perform visual Inspections
6.3.2 Perform metrology measurements with emphasis made to resolve impact of out of tolerance conditions.
6.3.3 Verify all tooling ball locations with respect to MTM data package.
6.3.4 Measure end flanges and compare with theoretical position.
Verified by: ______Date: ______
Lead Technician
6.4 Replace Port Flanges with Station 1 Assembly Flanges:
6.4.1 If attached remove the two horizontal port flanges covers and bag bolt assemblies for future use. See Figure 6-1.
Figure 6-1.
6.4.2 If attached remove NB port flange and bag bolt assemblies for future use. See Figure 6-2.
6.4.3 Install VV heating/cooling cryostat interface flanges by slipping each over each vertical port. The interface flanges need to be temporarily supported on the flanges. Reference drawing: se123-164. See Figure 6-2
N.B. port flange
6.4.4 Using rubber gasket material or gortex gasket material on the flanges for flange protection install stage one port assembly flange covers, support axle weldments, and hoist rings.
6.5 Install VVSA in Station One Rotating Fixture:
6.5.1 Using lift procedure (D-L-NCSX-XXXX) and test cell crane attached to Weldment hoist rings. Lift VV from a horizontal position and rotate to a vertical position. Check to see if VV is in a near vertical position. Mark CG location.
Note: If VV Cg is found to be off by a value greater than 2.0” return VV to its original position. Remove and relocate support axle Weldments to proper location and retest.
Verified by: ______Date: ______
Field Supervisor
6.5.2 Lubricate support axle and axle support cradle. Add lubricate to support axle weldment and support axle cradle components (cradle top and cradle base) to reduce VV rotation friction.
6.5.3 Mount VV on Station one rotating fixture in the horizontal position. See Figure 6-3.
Figure 6.3 Vacuum Vessel in Horizontal Position
6.5.4 Secure in place by bolting down support axle cradle to support blocks. See Figure 6-4.
6.5.5 Install quick release pin. See Figure 6-4.
6.5.6 Remove the hoist ring from worm gear side of VV support axle weldment. Install worm gear axle and worm gear. See Figure 6-4.
Figure 6.4 Installation Details
6.6 Metrology Set-up and Initial Vessel Measurements
6.6.1 Using a marker mark the positive toroidal field direction on the front and back surface of the vacuum vessel.
Note: The worm gear system is identified as the VV down direction. See Figure 6.5.
Verified by: ______Date: ______
Field Supervisor
6.6.2 Set up measurement fiducials provided by MTM plus add additional monuments as specified in FP Dimensional Control Plan for Station 1 (NCSXPLAFPA1DC-00). Rotate vessel to convenient access positions.
Note: Some monuments will be located on the body of the VVSA
6.6.3 Perform a best fit to the fiducial measurements using the monuments on the VV body. Settings will be made with the vessel NBI port at a +/-60º off vertical position as indicated in Figure 6-4 and Figure 6-5. Secure vessel position by inserting release pin and tighten support axle cradle bolts. Verify that the mounting system is rigid enough to meet FP Dimensional Control Plan metrology requirements.
Figure 6.5 Vacuum Vessel in Rotated Position
6.7 Marking Flux Loop Template and Heating Coolant Stud Locations:
6.7.1 Secure vessel position with the 60º NBI port at a +/– 60º off vertical position by inserting release pin and tighten support axle cradle bolts.
6.7.2 Mark surface for XXX loop placements with the vessel NBI port at a +/–60º off vertical position. It is expected that three Leica positions will be required on each side to accurately mark the vessel. The Leica metrology system will be used to accurately define four marks (within +/–0.040”) for each of the XXX loops except for the loops at the symmetry points which shall be positioned within +/–0.010”. The magnetic loop points shall be marked using an X to indicate the locating point. For ease of locating templates mark template number at center of four points. See figure 6.6 below and Reference drawing XXXXX and ProE model XXXXX for loop designation, point marking details and model geometry data.
Figure 6.6 Template Locating and Numbering
6.7.3 If not previously positioned rotate VV so that vessel NBI port is at a +/–60º off vertical position. See Figure 6-4.
6.7.4 The Leica metrology system will be used to locate XXXX studs per half period at X” spacing. Fine accuracy is not important position within +/– .50”. The stud location shall be marked with a circle with a name designation added ( A1, A2, A3….) to define the series. An outline of the coolant line and hold-down bracket shall also be marked. See Figure 6.7 and reference drawing se121-128 sheet 4 for loop designation, point marking details.
Note: The cooling lines overlay the diagnostic loops.
Figure 6-7 Overlay of the Coolant Lines Over the Diagnostic Loops
6.8 Vertical Port Component Installation
6.8.1 Mark heating/cooling support bracket A and B attachment studs and mark bracket clip outline.
6.8.2 Install cryostat interface mounting flange on vertical ports. Before welding the interface flange on the vertical ports the cryostat interface flange must be mover into the proper assembly position. ( See Figure 6-8).
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